System for integrated production of envelopes and contents thereof

ABSTRACT

A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system including at least one printing controller capable of receiving personalized printing data from at least one data source, the personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for the multiplicity of envelopes and is matched to individual envelope addresses, the at least one printing controller being operative to merge and order the personalized printing data from the at least one data source such that it is printed in a desired distribution sorting order, selected to optimize postal savings in bulk mailings and at least one production facility for the individually addressed sealed envelopes containing personalized printed material matched to individual addresses, each of the at least one production facility including at least one digital printer operative to print the personalized printing data including the envelope address information for a plurality of envelopes to be formed from a substrate and the personalized envelope contents information for contents of the plurality of envelopes, at least one cutting stage receiving a printed output from the at least one digital printer and being operative to cut at least one of envelope sheets according to an envelope shaped blank and envelope contents sheets, at least one content-containing envelope formation stage operative to wrap the envelope sheets over the envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto and a bundling stage, gathering and bundling the sealed individually addressed envelopes containing personalized contents matched thereto in the desired distribution sorting order.

REFERENCE TO RELATED APPLICATIONS

Reference is hereby made to U.S. Pat. No. 7,100,348, entitled Continuous Strip of Detachably Interconnected Folded Products, and to U.S. Published Patent Application 2006/0272295, which is a continuation of U.S. Pat. No. 7,100,348, the disclosures of which are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to mailing systems and methodologies generally and more particularly to integrated production of envelopes and the contents thereof.

BACKGROUND OF THE INVENTION

The following publications are believed to represent the current state of the art:

U.S. Pat. Nos. 1,801,155; 2,464,490; 2,610,784; 2,776,085; 2,783,935; 3,028,069; 3,228,586; 3,332,604; 3,557,519; 3,559,875; 3,626,821; 3,790,068; 3,897,720; 3,980,006; 3,998,138; 4,063,398; 4,066,206; 4,091,987; 4,437,852; 4,454,980; 4,497,509; 4,600,141; 4,630,768; 4,651,920; 4,694,632; 4,731,048; 4,804,135; 4,886,205; 4,896,821; 5,051,914; 5,072,401; 5,068,797; 5,069,384; 5,161,109; 5,398,867; 5,568,717; 5,640,831; 5,971,260; 7,231,750 and 7,254,931.

SUMMARY OF THE INVENTION

The present invention seeks to provide improved, cost effective mailing systems and methodologies. There is thus provided in accordance with a preferred embodiment of the present invention a system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system including at least one printing controller capable of receiving personalized printing data from at least one data source, the personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for the multiplicity of envelopes and is matched to individual envelope addresses, the at least one printing controller being operative to merge and order the personalized printing data from the at least one data source such that it is printed in a desired distribution sorting order, selected to optimize postal savings in bulk mailings and at least one production facility for the individually addressed sealed envelopes containing personalized printed material matched to individual addresses, each of the at least one production facility including at least one digital printer operative to print the personalized printing data including the envelope address information for a plurality of envelopes to be formed from a substrate and the personalized envelope contents information for contents of the plurality of envelopes, at least one cutting stage receiving a printed output from the at least one digital printer and being operative to cut at least one of envelope sheets according to an envelope shaped blank and envelope contents sheets, at least one content-containing envelope formation stage operative to wrap the envelope sheets over the envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto and a bundling stage, gathering and bundling the sealed individually addressed envelopes containing personalized contents matched thereto in the desired distribution sorting order.

In accordance with a preferred embodiment of the present invention the at least one printing controller is capable of receiving multiple printing jobs from disparate sources and combining them in a single pre-sorted print run. Preferably, the desired distribution sorting order is according to postal code. Additionally or alternatively, the desired distribution sorting order is according to the delivery order of a mailman's route.

In accordance with another preferred embodiment of the present invention the at least one production facility includes a plurality of production facilities geographically distributed close to correspondingly geographically distributed bulk mail drop-off locations. Preferably, the at least one content-containing envelope formation stage is operative to wrap the envelope sheets over the contents sheets in a manner such that side flaps of the envelope are glued to a surface of the envelope. Additionally or alternatively, the at least one cutting stage is capable of receiving the printed output from the at least one digital printer in at least two of roll, sheet and fan-fold form.

In accordance with yet another preferred embodiment of the present invention the at least one cutting stage operates asynchronously to the operation of the at least one content-containing envelope formation stage. Preferably, the at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving the printed output from the at least one digital printer and being operative to differentiate the envelope sheets from the envelope contents sheets prior to cutting the at least one of envelope sheets and envelope contents sheets. Additionally or alternatively, the envelopes include personalized printing both on the front and the back thereof.

In accordance with a further preferred embodiment of the present invention the contents of the envelopes is printed on a different substrate than the substrate. Preferably, envelope contents sheets are folded prior to the at least one content-containing envelope formation stage, such that the at least one content-containing envelope formation stage is operative to wrap the envelope sheets over suitably folded envelope contents sheets. Additionally or alternatively, prior to the at least one content-containing envelope formation stage at least one insert is placed over the envelope sheets, such that during the at least one content-containing envelope formation stage the envelope sheets are wrapped over the envelope contents sheets and the at least one insert.

In accordance with yet a further preferred embodiment of the present invention the at least one digital printer is operative to print the envelope address information separately from printing the personalized envelope contents information, the at least one cutting stage includes a plurality of cutting stages, at least one of the plurality of cutting stages receiving a first printed output corresponding to the envelope address information and being operative to cut the first printed output into the envelope sheets and at least one other of the plurality of cutting stages receiving a second printed output corresponding to the personalized envelope contents information and being operative to cut the second printed output-into the envelope contents sheets, and wherein the envelope sheets formed of the first printed output and the envelope contents sheets formed of the second printed output are merged in the at least one content-containing envelope formation stage.

There is further provided in accordance with a further preferred embodiment of the present invention a system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system including at least one digital printer operative to print personalized printing data including envelope address information for a multiplicity of envelopes to be formed from a substrate and personalized envelope contents information for contents of the multiplicity of envelopes, the contents of the multiplicity of envelopes containing a variable number of sheets, which varies from one of the multiplicity of envelopes to another of the multiplicity of envelopes and at least one content-containing envelope formation stage operative to wrap envelope sheets over envelope contents sheets containing a variable number of sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto having a variable number of sheets.

In accordance with a preferred embodiment of the present invention the at least one content-containing envelope formation stage is operative to wrap the envelope sheets over the envelope contents sheets in a manner such that side flaps of the envelope are glued to a surface of the envelope. Preferably, envelope contents sheets are folded prior to the at least one content-containing envelope formation stage, such that the at least one content-containing envelope formation stage is operative to wrap the envelope sheets over suitably folded envelope contents sheets.

In accordance with another preferred embodiment of the present invention the system also includes at least one cutting stage capable of receiving printed output from the at least one digital printer in at least two of roll, sheet and fan-fold form and being operative to cut the printed output into at least one of the envelope sheets and the envelope contents sheets, the envelope sheets being cut according to an envelope shaped blank. Preferably, the at least one cutting stage operates asynchronously to the operation of the at least one content-containing envelope formation stage. Additionally or alternatively, the at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving the printed output and being operative to differentiate the envelope sheets from the envelope contents sheets prior to cutting the at least one of the envelope sheets and the envelope contents sheets.

In accordance with yet another preferred embodiment of the present invention sealed individually addressed envelopes include personalized printing both on the front and the back thereof. Preferably, prior to the at least one content-containing envelope formation stage, at least one insert is placed over the envelope sheets, such that during the at least one content-containing envelope formation stage the envelope sheets are wrapped over the envelope contents sheets and the at least one insert.

There is additionally provided in accordance with an additional preferred embodiment of the present invention a system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system including at least one digital printer operative to print personalized printing data including envelope address information for a multiplicity of envelopes to be formed from a substrate and personalized envelope contents information for contents of the multiplicity of envelopes and at least one content-containing envelope formation stage operative to wrap envelope sheets over envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto, the sealed individually addressed envelopes including personalized printing both on the front and the back thereof.

In accordance with a preferred embodiment of the present invention the at least one content-containing envelope formation stage is operative to wrap the envelope sheets over the envelope contents sheets in a manner such that side flaps of the envelope are glued to a surface of the envelope. Preferably, the envelope contents sheets are folded prior to the at least one content-containing envelope formation stage, such that the at least one content-containing envelope formation stage is operative to wrap the envelope sheets over suitably folded envelope contents sheets.

In accordance with another preferred embodiment of the present invention the system also includes at least one cutting stage capable of receiving printed output from the at least one digital printer in at least two of roll, sheet and fan-fold form, and being operative to cut the printed output into at least one of the envelope sheets and the envelope contents sheets. Preferably, the at least one cutting stage operates asynchronously to the operation of the at least one content-containing envelope formation stage. Additionally or alternatively, the at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving the printed output and being operative to differentiate the envelope sheets from the envelope contents sheets prior to cutting the at least one of the envelope sheets and the envelope contents sheets.

In accordance with a further preferred embodiment of the present invention, prior to the at least one content-containing envelope formation stage, at least one insert is placed over the envelope sheets, such that during the at least one content-containing envelope formation stage the envelope sheets are wrapped over the envelope contents sheets and the at least one insert.

There is also provided in accordance with another preferred embodiment of the present invention a system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system including at least one digital printer operative to print personalized printing data including envelope address information for a multiplicity of envelopes to be formed from a substrate and personalized envelope contents information for contents of the multiplicity of envelopes, at least one cutting stage receiving a printed output from the at least one digital printer and being operative to cut at least one of envelope sheets and envelope contents sheets, at least one content-containing envelope formation stage operative to wrap the envelope sheets over the envelope contents sheets and thereby coterminously create envelopes and the content thereof in sealed individually addressed envelopes containing personalized content matched thereto.

In accordance with a preferred embodiment of the present invention the at least one content-containing envelope formation stage is operative to wrap the envelope sheets over envelope contents sheets containing a variable number of sheets, such that the sealed individually addressed envelopes have a variable number of sheets. Preferably, the at least one content-containing envelope formation stage is operative to wrap the envelope sheets over the envelope contents sheets in a manner such that side flaps of the envelope are glued to a surface of the envelope. Additionally or alternatively, the envelope contents sheets are folded prior to the at least one content-containing envelope formation stage, such that the at least one content-containing envelope formation stage is operative to wrap the envelope sheets over suitably folded envelope contents sheets.

In accordance with another preferred embodiment of the present invention the at least one cutting stage is capable of receiving the printed output from the at least one digital printer in at least two of roll, sheet and fan-fold form. Preferably, the sealed individually addressed envelopes include personalized printing both on the front and the back thereof. Additionally or alternatively, the at least one cutting stage operates asynchronously to the operation of the at least one content-containing envelope formation stage.

In accordance with a further preferred embodiment of the present invention the at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving the printed output and being operative to differentiate the envelope sheets from the envelope contents sheets prior to cutting the at least one of the envelope sheets and the envelope contents sheets. Preferably, prior to the at least one content-containing envelope formation stage, at least one insert is placed over the envelope sheets, such that during the at least one content-containing envelope formation stage the envelope sheets are wrapped over the envelope contents sheets and the at least one insert.

There is further provided in accordance with a further preferred embodiment of the present invention a system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system including at least one printing controller capable of receiving personalized printing data from at least one data source, the personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for the multiplicity of envelopes and is matched to individual envelope addresses, the at least one printing controller being operative to order the personalized printing data from the at least one data source such that it is printed in a desired distribution sorting order, selected to optimize postal savings in bulk mailings and at least one production facility for producing the individually addressed sealed envelopes containing personalized printed material matched to individual addresses, each of the at least one production facility including at least one printer operative to print the personalized printing data including envelope address information for a plurality of envelopes and personalized envelope contents information for contents of the plurality of envelopes, at least one envelope/envelope contents differentiation stage receiving a printed output from the at least one printer and being operative to provide envelope sheets and envelope contents sheets, at least one content-containing envelope formation stage operative to wrap the envelope sheets over the envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto and a bundling stage, gathering and bundling the sealed individually addressed envelopes containing personalized contents matched thereto in the desired distribution sorting order.

In accordance with a preferred embodiment of the present invention the at least one printing controller is capable of receiving multiple printing jobs from disparate sources and combining them in a single pre-sorted print run. Preferably, the desired distribution sorting order is according to postal code. Additionally or alternatively, the desired distribution sorting order is according to the delivery order of a mailman's route.

In accordance with another preferred embodiment of the present invention the at least one production facility includes a plurality of production facilities geographically distributed close to correspondingly geographically distributed bulk mail drop-off locations. Preferably, the at least one content-containing envelope formation stage is operative to wrap the envelope sheets over the contents sheets in a manner such that side flaps of the envelope are glued to a surface of the envelope. Additionally or alternatively, the at least one envelope/envelope contents differentiation stage is capable of receiving the printed output in at least two of roll, sheet and fan-fold form.

In accordance with a further preferred embodiment of the present invention the at least one envelope/envelope contents differentiation stage operates asynchronously to the operation of the at least one content-containing envelope formation stage. Preferably, the envelopes include personalized printing both on the front and the back thereof. Additionally or alternatively, the envelope contents sheets are folded prior to the at least one content-containing envelope formation stage, such that the at least one content-containing envelope formation stage is operative to wrap the envelope sheets over suitably folded envelope contents sheets.

In accordance with yet a further preferred embodiment of the present invention, prior to the at least one content-containing envelope formation stage, at least one insert is placed over the envelope sheets, such that during the at least one content-containing envelope formation stage the envelope sheets are wrapped over the envelope contents sheets and the at least one insert.

There is additionally provided in accordance with an additional preferred embodiment of the present invention a method for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the method including receiving personalized printing data from at least one data source, the personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for the multiplicity of envelopes and is matched to individual envelope addresses, ordering the personalized printing data from the at least one data source such that it is printed in a desired distribution sorting order, selected to optimize postal savings in bulk mailings and producing the individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the producing including printing the personalized printing data, thereby providing a multiplicity of envelope sheets and envelope content sheets for the multiplicity of envelopes, differentiating the envelope sheets and the envelope contents sheets, wrapping the envelope sheets over the envelope contents sheets and thereby creating sealed individually addressed envelopes containing personalized content matched thereto and gathering and bundling the sealed individually addressed envelopes containing personalized contents matched thereto in the desired distribution sorting order.

In accordance with a preferred embodiment of the present invention the printing the personalized printing data includes digital printing. Preferably, the digital printing includes digital printing on a continuous substrate. Additionally or alternatively, the receiving includes receiving multiple printing jobs from disparate sources and combining them in a single pre-sorted print run.

In accordance with another preferred embodiment of the present invention the desired distribution sorting order is according to postal code. Preferably, the desired distribution sorting order is according to the delivery order of a mailman's route. Additionally or alternatively, the wrapping includes wrapping the envelope sheets over contents sheets such that side flaps of the envelope are glued to a surface of the envelope.

In accordance with yet another preferred embodiment of the present invention the method also includes, prior to the wrapping, folding the envelope contents sheets, such that the wrapping includes wrapping the envelope sheets over suitably folded envelope contents sheets. Preferably, the method also includes, prior to the wrapping, placing at least one insert is placed over the envelope sheets, such that the wrapping includes wrapping the envelope sheets over the envelope contents sheets and the at least one insert.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:

FIG. 1 is a simplified schematic illustration of a system providing real-time, integrated production of envelopes and the contents thereof in accordance with a preferred embodiment of the present invention;

FIGS. 2A and 2B are simplified, schematic illustrations of two alternative embodiments of a cutting and/or envelope/envelope contents differentiation stage forming part of the system of FIG. 1;

FIGS. 3A and 3B are simplified, schematic illustrations of two alternative embodiments of an envelope formation stage forming part of the system of FIG. 1; and

FIG. 4 is a simplified, schematic illustration of a sealing stage and a bundling stage forming part of the system of FIG. 1.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference is now made to FIG. 1, which is a simplified schematic illustration of a system providing real-time, integrated production of envelopes and the contents thereof in accordance with a preferred embodiment of the present invention. The system of FIG. 1 preferably comprises at least one production facility 100 for the production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses.

Preferably, the production facilities 100 may be geographically distributed so as to be adjacent to bulk mail drop-off locations of postal authorities or delivery contractors. It is appreciated that such locations may be in different countries or in different regions of a single country. The postal authorities or delivery contractors at different ones of such locations may require different franking. It is a particular feature of the present invention that due to the real-time operation of the system, a given production facility 100 may be selected at a given time in order to take advantage of beneficial spot pricing of bulk mail delivery services by a postal authority or delivery contractor.

Each production facility 100 preferably includes at least one high speed digital printer 101, such as, for example, a IBM infoprint 2105ES, commercially available from IBM Corporation of Armonk, N.Y., a Konica Minolta Bizhub Pro 1050P, commercially available from Konica Minolta Holdings Inc. of Tokyo, Japan, or a Ricoh DDP184, commercially available from Ricoh Corporation of Tokyo, Japan, which is capable of printing on a substrate, such as paper on one or more white rolls 102. Alternatively, the paper may be provided to printer 101 as cut sheets, fan-fold stacks or in any other suitable form, and may be of any suitable color, thickness or width. Each digital printer 101 preferably receives printing instructions from at least one printing controller 110, which, in turn, receives personalized printing data from one or more data sources 112. The personalized printing data includes envelope addresses and often includes personalized envelope contents which vary and are keyed to specific envelope addresses.

In accordance with a preferred embodiment of the present invention the controller 110 imposes the envelope addresses and other envelope information into the stream of information provided to one or more printers 101, such that the envelope information is printed onto an envelope or into an envelope information sheet to be inserted into a windowed envelope.

It is a particular embodiment of the present invention that the envelope information may be printed onto the envelope or onto the envelope information sheet via a different printing stream than the stream that prints envelope contents pages, or alternatively, that the envelope information and envelope contents pages are printed in a single stream.

It is a particular feature of the present invention that printing controller 110 may receive personalized printing data from multiple disparate sources 112, such as banks, utilities, insurance companies and other customers, each relating to a printing piece which may vary in its dimensions, number of pages of content and other parameters. Preferably, the printing controller 110 commingles the data received from multiple disparate sources 112 and orders the personalized printing data from such multiple disparate sources 112 such that it is printed and thus output in a desired distribution sorting order. The distribution sorting order is preferably selected to maximize savings in postage and may be according to postal code and even more preferably in the delivery order of a mailman's route. Ordering the printing in such an order enables very significant discounts in postage to be realized without requiring downstream sorting. The amount of such discounts may exceed the cost of producing the mailing piece.

Alternatively, printing controller 110 may receive personalized printing data from a single source 112, relating to a printing piece which may vary in its dimensions, number of pages of content and other parameters. In this embodiment, printing controller 110 orders the personalized printing data from the single source 112 such that it is printed and thus output in a desired distribution sorting order. The distribution sorting order is preferably selected to maximize savings in postage and may be according to postal code and even more preferably in the delivery order of a mailman's route. Ordering the printing in such an order enables very significant discounts in postage to be realized without requiring downstream sorting. The amount of such discounts may exceed the cost of producing the mailing piece.

It is also a particular feature of the present invention that multiple digital printers 101 may be located adjacent multiple mailing locations and that a digital printer 101 may be selected according to its propinquity to a bulk mail drop off location, in order to provide additional cost savings in transport. It is appreciated that a printing controller 110 may divide a printing job from a given source 112 into multiple printing jobs to be handled by various digital printers 101, each optimally located nearby a bulk mail drop off location for a given group of addresses.

It is appreciated that the digital printer 101 prints personalized envelope and envelope contents information on one or both sides of the substrate, prior to envelope formation, thus enabling, inter alia, printing on the interior of envelopes. The digital printer 101 may provide a printed output in one or more forms, such as fan-folded stacks 114, cut stacks of sheets 116 and rolls 118. The digital printer 101 may operate asynchronously with respect to the remainder of the system.

Referring additionally now to FIGS. 2A and 2B, which illustrate two alternative embodiments of a cutting and/or envelope/envelope contents differentiation stage forming part of the system of FIG. 1.

As seen in FIGS. 2A, downstream of each digital printer 101 there is preferably provided a cutting and envelope/envelope contents differentiation stage 120 at which printed envelope sheets 122 are cut, preferably according to an envelope blank and preferably by a suitable die cutter 123, and the printed envelope contents are cut into one or more envelope contents sheets 124 and trimmed as necessary by a side trimmer 126. Preferably, a scanning functionality (not shown), identifies pages coming out of the printer as envelope sheets or as envelope contents sheets, and directs them toward the suitable trimming device, such as the die cutter 123 or the side trimmer 126. A preferred scanning functionality is that described in U.S. Pat. No. 5,008,520, the contents of which are hereby incorporated by reference. It is appreciated that any suitable cutting method is suitable, such as laser cutting or water jet cutting.

In the illustrated embodiment of FIG. 2A, envelope sheets 122 are separated from envelope contents sheets 124 prior to die cutting and trimming. Paper scraps are removed preferably by vacuum. Alternatively, the envelope sheets 122 may be joined to the envelope contents sheets 124 as described in U.S. Pat. No. 7,100,348, the disclosure of which is hereby incorporated by reference.

Turning to FIG. 2B, it is seen that downstream of each digital printer 101 there is preferably provided a cutting stage 120. As seen in FIG. 2B, the printed envelope sheets 122 are provided in a first stream, having a first cutting stage 127, at which printed envelope sheets 122 are cut, preferably according to an envelope blank and preferably by suitable die cutter 123, and the printed envelope contents are provided in a second stream having a second cutting stage 128, at which the envelope contents are cut into one or more envelope contents sheets 124 and trimmed as necessary by side trimmer 126. It is appreciated that the envelope sheets and envelope content sheets may be printed and cut out of different substrates, here shown as a fan fold stack of sheets and a roll of sheets, and as substrates of different colors. It is appreciated that any suitable cutting method is suitable, such as laser cutting or water jet cutting.

In the illustrated embodiment of FIG. 2B, paper scraps are removed preferably by vacuum. Alternatively, the envelope sheets 122 may be joined to the envelope contents sheets 124 as described in U.S. Pat. No. 7,100,348, the disclosure of which is hereby incorporated by reference.

It is appreciated that, as seen in FIGS. 2A and 2B, the number of envelope contents sheets 124 may vary from envelope to envelope. All the envelope contents sheet 124 belonging to a specific envelope are preferably accumulated by an accumulator 129, and then continue to move through the system as a group of accumulated envelope contents sheets 124. Envelope contents sheets 124 belonging to a single envelope are preferably identified by a scanning functionality (not shown), preferably that described in U.S. Pat. No. 5,008,520, the contents of which are hereby incorporated by reference. It is further appreciated that the die cutter 123 of stage 120 preferably operates asynchronously from the envelope formation stage which follows.

Alternatively, envelope sheets 122 and envelope content sheets 124 may be produced by any other suitable means and supplied to the envelope formation stage which follows.

Returning to FIG. 1, it is seen that downstream of the cutting and/or envelope/envelope contents differentiation stage 120 is a content containing envelope formation stage 130 at which the envelope 132 is formed by folding the envelope sheet 122 over the envelope contents sheet or sheets 124 and gluing a back flap of the envelope sheet 122 and side flaps of the envelope sheet 122 respectively. At this stage externally produced inserts may be added to the envelope contents. Envelope formation stage 130 is described further hereinbelow with reference to FIGS. 3A, 3B and 4.

In accordance with a preferred embodiment of the present invention, at a bundling stage 140, the finished mailers 142, each including an envelope 132 and its content sheets 124, are gathered and bundled in a desired distribution order for delivery to the postal delivery contractor. A suitable stacking and bundling system is described in U.S. Pat. No. 6,682,067, the disclosure of which is hereby incorporated by reference. It is noted that where multiple printing jobs from disparate sources are preferably combined in a single print run, bundles 150 may contain mailers of differing sizes and configurations, multiple ones of which may be directed to the same addressee from different senders.

Reference is now made additionally to FIGS. 3A and 3B, which illustrate two alternative embodiments of the structure and operation of envelope formation stage 130.

In the embodiment illustrated in FIG. 3A, envelope 132 is formed by transversely scoring envelope sheet 122 and subsequently folding the envelope sheet 122 over the suitably folded envelope contents sheet or sheets 124 and gluing a back flap 155 and side flaps 156, respectively. It is appreciated that at the envelope formation stage 130 an inside flap envelope or an outside flap envelope may be formed, depending on the order in which the back flap 155 and side flaps 156 are glued to each other and on the surface of each of the flaps to which the glue is applied.

As seen in FIG. 3A, suitably die cut envelope sheets 122 are received along a first conveyor 200, back flap 155 facing forwardly, and envelope contents sheets 124, to be enclosed within the envelope to be formed from a corresponding envelope sheet 122, are received along a second conveyor 202 by accumulator 129. The accumulated envelope contents sheets 124 are then folded as desired, typically in half or into three portions, by an envelope contents sheet folder 204, which is typically a buckle shoot folder.

The envelope sheet 122 is preferably transversely scored by a scoring mechanism 205. The folded envelope contents sheets 124 are positioned over a middle panel of the envelope sheet 122, preferably by a suitable positioner, such as a positioner including servo controlled nips (not shown), and released in synchronization with the location of corresponding envelope sheet 122. Alternatively, the envelope contents sheet folder 204 may also function as a positioner for the envelope contents sheets 124. Optionally, one or more inserts 158 may be placed onto the envelope sheet 122 by an insert feeder 208. Preferably, inserts 158 are also positioned by a suitable positioner (not shown), such as a positioner including servo controlled nips.

In accordance with a preferred embodiment of the present invention, envelope sheet 122 and the envelope contents sheets 124 are merged together precisely by the positioner to allow for a high degree of placement precision, regardless of the envelope processing speed. This is preferably achieved by varying the speed of conveyor 202 such that the envelope contents sheets 124 meet the appropriate envelope and are merged together precisely. The positioner also provides a high degree of placement precision independent of the size of the content pages vis-à-vis the envelope size and allows for a varying number of contents sheets 124 to be placed in each envelope.

The envelope sheet 122, having thereon the folded envelope contents sheets 124, and optionally inserts 158, is then folded around content sheets 124 and optional inserts 158 by a suitable folder 210.

Alternatively, as shown in FIG. 3B, envelope 132 is formed by folding the envelope sheet 122 together with the envelope contents sheet or sheets 124 and gluing back flap 155 and side flaps 156, respectively. It is appreciated that at the envelope formation stage 130 an inside flap envelope or an outside flap envelope may be formed, depending on the order in which the back flap 155 and side flaps 156 are glued to each other and on the surface of each of the flaps to which the glue is applied.

Suitably die cut envelope sheets 122 are received along a first conveyor 200, back flap 155 forwardly, and envelope contents sheets 124, to be enclosed within the envelope to be formed from a corresponding envelope sheet 122, are received along a second conveyor 202 by accumulator 129 and released by a positioner 212, including servo controlled nips, in synchronization with the location of corresponding envelope sheet 122. Such synchronization is preferably achieved by varying the speed of conveyor 202 in accordance with the speed of conveyor 200. This synchronization preferably results in precise positioning of the envelope contents sheets 124.

Optionally, one or more inserts 158 may be placed onto the envelope sheet 122 by insert feeder 208. Preferably, inserts 158 are also positioned by a suitable positioner, such as a positioner including servo controlled nips.

Positioner 212 preferably allows for a high degree of placement precision, regardless of the envelope processing speed. The positioner 212 provides a high degree of placement precision independent of the size of the content pages vis-à-vis the envelope size and also allows for a varying number of contents sheets 124 to be placed in each envelope.

The envelope sheet 122 having the envelope contents sheets 124, and optionally inserts 158 thereon, enter buckle chute folder 214, which folds the envelope sheet 122, content sheets 124 and optional inserts 158.

Reference is now made additionally to FIG. 4, which illustrates a sealing stage and a bundling stage forming part of the system of FIG. 1. As seen in FIG. 4, side flaps 156 are scored by a scoring mechanism 216, and glue is then applied to side flaps 156, such as by glue applicator 218. Alternatively, the glue may be applied to the back flap 155. Glue can be applied in the form of hot or cold melt glue, or using any suitable method, including strip application. Side flaps 156 are then folded over contents sheets 124 and envelope sheet 122 by any suitable folding method, such as by using a plow folder. Alternatively, as shown in the embodiment of FIG. 3B, glue is applied to side flaps 156 or to back flap 155 as the last part of the buckle folding process.

In another alternative embodiment, scoring is performed upstream, in either the cutting or the merging modules, glue is applied to back flap 155 or to side flaps 156 in the folder module or in a separate module, and side flaps 156 are folded under the back flap 155 of the envelope sheet 122, yielding an envelope with “inside flaps” or over the back flap 155 of the envelope sheet 122, yielding an envelope with “outside flaps”.

As seen further in FIG. 4, the direction of envelope travel is changed by 90 degrees, a top flap 222 of the envelope sheet 122 is scored by scoring mechanism 230, glue is applied thereto, such as by applicator 232, and top flap 222 is folded over, by any suitable folding method, such as by using a plow folder 234, thus sealing the envelope. Alternatively, glue may be applied to the back flap 155, onto which the top flap 222 is folded. Finished mailers 142 are preferably laying flat while they are scored, glued and sealed to facilitate operation for postal franking machines. It is appreciated that finished mailers 142 may need to be flipped prior to franking.

As seen further in FIG. 4, finished mailers 142 are preferably turned up on edge and moved into a vertical stacking mechanism. Alternatively, envelopes are turned on edge prior to scoring and gluing of top flaps 222, which are scored and glued while the envelopes are in a vertical position. The finished mailers 142 are then preferably stacked on edge and grouped into bundles 150 as seen in FIG. 3B.

It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the invention includes both combinations and subcombinations of the various features described hereinabove as well as modifications and variations thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not in the prior art. 

1. A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system comprising: at least one printing controller capable of receiving personalized printing data from at least one data source, said personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for said multiplicity of envelopes and is matched to individual envelope addresses, said at least one printing controller being operative to merge and order said personalized printing data from said at least one data source such that it is printed in a desired distribution sorting order, selected to optimize postal savings in bulk mailings; and at least one production facility for said individually addressed sealed envelopes containing personalized printed material matched to individual addresses, each of said at least one production facility comprising: at least one digital printer operative to print said personalized printing data including said envelope address information for a plurality of envelopes to be formed from a substrate and said personalized envelope contents information for contents of said plurality of envelopes; at least one cutting stage receiving a printed output from said at least one digital printer and being operative to cut at least one of envelope sheets according to an envelope shaped blank and envelope contents sheets; at least one content-containing envelope formation stage operative to wrap said envelope sheets over said envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto; and a bundling stage, gathering and bundling said sealed individually addressed envelopes containing personalized contents matched thereto in said desired distribution sorting order.
 2. A system according to claim 1 and wherein said at least one printing controller is capable of receiving multiple printing jobs from disparate sources and combining them in a single pre-sorted print run.
 3. A system according to claim 1 and wherein said desired distribution sorting order is according to postal code.
 4. A system according to claim 3 and wherein said desired distribution sorting order is according to the delivery order of a mailman's route.
 5. A system according to claim 1 and wherein said at least one production facility comprises a plurality of production facilities geographically distributed close to correspondingly geographically distributed bulk mail drop-off locations.
 6. A system according to claim 1 and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over said contents sheets in a manner such that side flaps of said envelope are glued to a surface of said envelope.
 7. A system according to claim 1 and wherein said at least one cutting stage is capable of receiving said printed output from said at least one digital printer in at least two of roll, sheet and fan-fold form.
 8. A system according to claim 1 and wherein said at least one cutting stage operates asynchronously to the operation of said at least one content-containing envelope formation stage.
 9. A system according to claim 1 and wherein said at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving said printed output from said at least one digital printer and being operative to differentiate said envelope sheets from said envelope contents sheets prior to cutting said at least one of envelope sheets and envelope contents sheets.
 10. A system according to claim 1 and wherein said envelopes include personalized printing both on the front and the back thereof.
 11. A system according to claim 1 and wherein said contents of said envelopes is printed on a different substrate than said substrate.
 12. A system according to claim 1 and wherein said envelope contents sheets are folded prior to said at least one content-containing envelope formation stage, such that said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over suitably folded envelope contents sheets.
 13. A system according to claim 1 and wherein: said at least one digital printer is operative to print said envelope address information separately from printing said personalized envelope contents information, said at least one cutting stage comprises a plurality of cutting stages, at least one of said plurality of cutting stages receiving a first printed output corresponding to said envelope address information and being operative to cut said first printed output into said envelope sheets and at least one other of said plurality of cutting stages receiving a second printed output corresponding to said personalized envelope contents information and being operative to cut said second printed output into said envelope contents sheets, and wherein said envelope sheets formed of said first printed output and said envelope contents sheets formed of said second printed output are merged in said at least one content-containing envelope formation stage.
 14. A system according to claim 1 and wherein prior to said at least one content-containing envelope formation stage at least one insert is placed over said envelope sheets, such that during said at least one content-containing envelope formation stage said envelope sheets are wrapped over said envelope contents sheets and said at least one insert.
 15. A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system comprising: at least one digital printer operative to print personalized printing data including envelope address information for a multiplicity of envelopes to be formed from a substrate and personalized envelope contents information for contents of said multiplicity of envelopes, said contents of said multiplicity of envelopes containing a variable number of sheets, which varies from one of said multiplicity of envelopes to another of said multiplicity of envelopes; and at least one content-containing envelope formation stage operative to wrap envelope sheets over envelope contents sheets containing a variable number of sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto having a variable number of sheets.
 16. A system according to claim 15 and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over said envelope contents sheets in a manner such that side flaps of said envelope are glued to a surface of said envelope.
 17. A system according to claim 15 and wherein said envelope contents sheets are folded prior to said at least one content-containing envelope formation stage, such that said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over suitably folded envelope contents sheets.
 18. A system according to claim 15 and also comprising at least one cutting stage capable of receiving printed output from said at least one digital printer in at least two of roll, sheet and fan-fold form and being operative to cut said printed output into at least one of said envelope sheets and said envelope contents sheets, said envelope sheets being cut according to an envelope shaped blank.
 19. A system according to claim 18 and wherein said at least one cutting stage operates asynchronously to the operation of said at least one content-containing envelope formation stage.
 20. A system according to claim 18 and wherein said at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving said printed output and being operative to differentiate said envelope sheets from said envelope contents sheets prior to cutting said at least one of said envelope sheets and said envelope contents sheets.
 21. A system according to claim 15 and wherein said sealed individually addressed envelopes include personalized printing both on the front and the back thereof.
 22. A system according to claim 15 and wherein, prior to said at least one content-containing envelope formation stage, at least one insert is placed over said envelope sheets, such that during said at least one content-containing envelope formation stage said envelope sheets are wrapped over said envelope contents sheets and said at least one insert.
 23. A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system comprising: at least one digital printer operative to print personalized printing data including envelope address information for a multiplicity of envelopes to be formed from a substrate and personalized envelope contents information for contents of said multiplicity of envelopes; and at least one content-containing envelope formation stage operative to wrap envelope sheets over envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto, said sealed individually addressed envelopes including personalized printing both on the front and the back thereof.
 24. A system according to claim 23 and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over said envelope contents sheets in a manner such that side flaps of said envelope are glued to a surface of said envelope.
 25. A system according to claim 23 and wherein said envelope contents sheets are folded prior to said at least one content-containing envelope formation stage, such that said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over suitably folded envelope contents sheets.
 26. A system according to claim 23 and also comprising at least one cutting stage capable of receiving printed output from said at least one digital printer in at least two of roll, sheet and fan-fold form, and being operative to cut said printed output into at least one of said envelope sheets and said envelope contents sheets, said envelope sheets being cut into according to an envelope shaped blank.
 27. A system according to claim 26 and wherein said at least one cutting stage operates asynchronously to the operation of said at least one content-containing envelope formation stage.
 28. A system according to claim 26 and wherein said at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving said printed output and being operative to differentiate said envelope sheets from said envelope contents sheets prior to cutting said at least one of said envelope sheets and said envelope contents sheets.
 29. A system according to claim 23 and wherein, prior to said at least one content-containing envelope formation stage, at least one insert is placed over said envelope sheets, such that during said at least one content-containing envelope formation stage said envelope sheets are wrapped over said envelope contents sheets and said at least one insert.
 30. A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system comprising: at least one digital printer operative to print personalized printing data including envelope address information for a multiplicity of envelopes to be formed from a substrate and personalized envelope contents information for contents of said multiplicity of envelopes; at least one cutting stage receiving a printed output from said at least one digital printer and being operative to cut at least one of envelope sheets and envelope contents sheets; at least one content-containing envelope formation stage operative to wrap said envelope sheets over said envelope contents sheets and thereby coterminously create envelopes and the content thereof in sealed individually addressed envelopes containing personalized content matched thereto.
 31. A system according to claim 30 and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over envelope contents sheets containing a variable number of sheets, such that said sealed individually addressed envelopes have a variable number of sheets.
 32. A system according to claim 30 and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over said envelope contents sheets in a manner such that side flaps of said envelope are glued to a surface of said envelope.
 33. A system according to claim 30 and wherein said envelope contents sheets are folded prior to said at least one content-containing envelope formation stage, such that said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over suitably folded envelope contents sheets.
 34. A system according to claim 30 and wherein said at least one cutting stage is capable of receiving said printed output from said at least one digital printer in at least two of roll, sheet and fan-fold form.
 35. A system according to claim 30 and wherein said sealed individually addressed envelopes include personalized printing both on the front and the back thereof.
 36. A system according to claim 30 and wherein said at least one cutting stage operates asynchronously to the operation of said at least one content-containing envelope formation stage.
 37. A system according to claim 30 and wherein said at least one cutting stage includes an envelope/envelope contents differentiation stage, receiving said printed output and being operative to differentiate said envelope sheets from said envelope contents sheets prior to cutting said at least one of said envelope sheets and said envelope contents sheets.
 38. A system according to claim 30 and wherein, prior to said at least one content-containing envelope formation stage, at least one insert is placed over said envelope sheets, such that during said at least one content-containing envelope formation stage said envelope sheets are wrapped over said envelope contents sheets and said at least one insert.
 39. A system for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the system comprising: at least one printing controller capable of receiving personalized printing data from at least one data source, said personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for said multiplicity of envelopes and is matched to individual envelope addresses, said at least one printing controller being operative to order said personalized printing data from said at least one data source such that it is printed in a desired distribution sorting order, selected to optimize postal savings in bulk mailings; and at least one production facility for producing said individually addressed sealed envelopes containing personalized printed material matched to individual addresses, each of said at least one production facility comprising: at least one printer operative to print said personalized printing data including envelope address information for a plurality of envelopes and personalized envelope contents information for contents of said plurality of envelopes; at least one envelope/envelope contents differentiation stage receiving a printed output from said at least one printer and being operative to provide envelope sheets and envelope contents sheets; at least one content-containing envelope formation stage operative to wrap said envelope sheets over said envelope contents sheets and thereby create sealed individually addressed envelopes containing personalized content matched thereto; and a bundling stage, gathering and bundling said sealed individually addressed envelopes containing personalized contents matched thereto in said desired distribution sorting order.
 40. A system according to claim 39 and wherein said at least one printing controller is capable of receiving multiple printing jobs from disparate sources and combining them in a single pre-sorted print run.
 41. A system according to claim 39 and wherein said desired distribution sorting order is according to postal code.
 42. A system according to claim 41 and wherein said desired distribution sorting order is according to the delivery order of a mailman's route.
 43. A system according to claim 39 and wherein said at least one production facility comprises a plurality of production facilities geographically distributed close to correspondingly geographically distributed bulk mail drop-off locations.
 44. A system according to claim 39 and wherein said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over said contents sheets in a manner such that side flaps of said envelope are glued to a surface of said envelope.
 45. A system according to claim 39 and wherein said at least one envelope/envelope contents differentiation stage is capable of receiving said printed output in at least two of roll, sheet and fan-fold form.
 46. A system according to claim 39 and wherein said at least one envelope/envelope contents differentiation stage operates asynchronously to the operation of said at least one content-containing envelope formation stage.
 47. A system according to claim 39 and wherein said envelopes include personalized printing both on the front and the back thereof.
 48. A system according to claim 39 and wherein said envelope contents sheets are folded prior to said at least one content-containing envelope formation stage, such that said at least one content-containing envelope formation stage is operative to wrap said envelope sheets over suitably folded envelope contents sheets.
 49. A system according to claim 39 and wherein, prior to said at least one content-containing envelope formation stage, at least one insert is placed over said envelope sheets, such that during said at least one content-containing envelope formation stage said envelope sheets are wrapped over said envelope contents sheets and said at least one insert.
 50. A method for providing real-time, integrated production of individually addressed sealed envelopes containing personalized printed material matched to individual addresses, the method comprising: receiving personalized printing data from at least one data source, said personalized printing data including envelope address information for a multiplicity of envelopes and personalized envelope contents information which varies for said multiplicity of envelopes and is matched to individual envelope addresses; ordering said personalized printing data from said at least one data source such that it is printed in a desired distribution sorting order, selected to optimize postal savings in bulk mailings; and producing said individually addressed sealed envelopes containing personalized printed material matched to individual addresses, said producing comprising: printing said personalized printing data, thereby providing a multiplicity of envelope sheets and envelope content sheets for said multiplicity of envelopes; differentiating said envelope sheets and said envelope contents sheets; wrapping said envelope sheets over said envelope contents sheets and thereby creating sealed individually addressed envelopes containing personalized content matched thereto; and gathering and bundling said sealed individually addressed envelopes containing personalized contents matched thereto in said desired distribution sorting order.
 51. A method according to claim 50 and wherein said printing said personalized printing data comprises digital printing.
 52. A method according to claim 50 and wherein said digital printing comprises digital printing on a continuous substrate.
 53. A method according to claim 50 and wherein said receiving comprises receiving multiple printing jobs from disparate sources and combining them in a single pre-sorted print run.
 54. A method according to claim 50 and wherein said desired distribution sorting order is according to postal code.
 55. A method according to claim 54 and wherein said desired distribution sorting order is according to the delivery order of a mailman's route.
 56. A method according to claim 50 and wherein said wrapping comprises wrapping said envelope sheets over contents sheets such that side flaps of said envelope are glued to a surface of said envelope.
 57. A method according to claim 50 and also comprising, prior to said wrapping, folding said envelope contents sheets, such that said wrapping comprises wrapping said envelope sheets over suitably folded envelope contents sheets.
 58. A method according to claim 50 and also comprising, prior to said wrapping, placing at least one insert is placed over said envelope sheets, such that said wrapping comprises wrapping said envelope sheets over said envelope contents sheets and said at least one insert. 